Garage door insulation system

RELATED APPLICATIONS

0001This application is a divisional application of U.S. application Ser. No. 12/363,798, filed Feb. 2, 2009 and claims the benefit of U.S. Provisional Patent Application Ser. No. 61/026,906, filed on 7 Feb. 2008, both of which are incorporated by reference in their entirety.

BACKGROUND OF THE INVENTION

00021. Field of the Invention

0003This invention relates in general to insulation products, and more specifically to an insulation product particularly suited for use in conjunction with a garage door.

00042. Discussion of the Prior Art

0005A garage for a vehicle includes a garage door for entrance and exit of the vehicle. The garage door is a large rectangular door which usually includes an upper panel, a lower panel, and two center panels. The panels are connected to one another by hinges. A typical panel includes a frame along its upper and lower edges. The panel further includes a door tray inside the frame which defines a major surface. The door tray is recessed from the frame and it is generally flat, with the exception that a contour is formed in the door tray. The contour forms raised areas in the door tray. The garage door can be opened by sliding it upward on a pair of rails extending along the opening and ceiling of the garage.

0006A garage door is often provided with insulating material to provide thermal insulation and to attempt to dampen the sound. One type of conventional insulation for garage doors is plastic foam (polyethyelene or polystyrene) insulation. The insulation is secured to the interior of each door panel. The surface of a door panel is often contoured to produce an attractive design. Unfortunately, the plastic foam insulation is formed in relatively rigid sheets that are not adapted for the contours of a door panel.

0007One way to address this problem is to mold the plastic foam insulation to include recesses adapted to receive the contours of the door panel. Unfortunately, the molding process adds an extra step to the manufacture of the insulation so that it is more expensive to produce.

0008Other insulation systems for garage doors include a fibrous or other insulation material with a facing on one or both sides of the insulation layer. Installing the insulation includes friction fitting the edges of the insulation into the contours of the door trays of the garage door frame. If the insulation is not adhered to the garage door by means of an adhesive, the insulation is prone to falling out of the door or sagging.

0009Another insulation system includes an insulation having a facing including an adhesive on a substantial portion of the side of the insulation that is adjacent to the garage door. However, affixing the insulation to the door by means of an adhesive has proven to be very difficult and time consuming. It is difficult to control where the insulation will affix to the door and may not be removed or reinstalled easily if there is an error as to the placement of the insulation on the door.

0010Another alternative to adhering the insulation to the door includes taping the insulation to the edges of the door. However, over time, the tape becomes loose and the insulation is prone to falling off of the door.

0011In the past, there have been several garage door insulating “kits” in the market place. The majority of these kits-are made up of large pieces of foam board panels, which are bulky. Additionally, foam board panels have proven to be extremely difficult to install because of their rigidity. Further, they are extremely difficult to fit in a store display and to transport in an automobile.

0012Thus, it would be desirable to provide a garage door insulation system which overcomes the shortcomings of the conventional insulated garage door and provides a simple, convenient solution to consumers in the marketplace.

SUMMARY OF THE INVENTION

0013The insulation system of the present invention includes a panel having a major surface, a layer of insulating material and at least one securing clip affixed to the panel securing the insulation layer to the major surface.

0014According to this invention there is also provided a method of installing an insulation layer on a panel. The method includes the steps of (a) affixing at least one clip to a major surface of the panel, (b) positioning a portion of insulation material over a first connector of that clip so that the first connector extends through the insulation material and (c) connecting a second connector of that clip to the first connector so as to secure the insulation material to the panel.

0015In accordance with yet another aspect of the present invention a method is provided for installing an insulation layer on a garage door where that garage door includes a plurality of panels. The method includes the step of affixing at least one clip to a major surface of a first panel of the plurality of panels. The method further includes the step of positioning a first section of the insulation material over a first connector of that clip so that the first connector extends through the first section of the insulation material. In addition, the method includes connecting a second connector of that clip to the first connector so as to secure the first section of insulation material to the first panel. Additional sections of insulation material are mounted to additional panels of the plurality of panels in the same manner the first section of insulation material is mounted to the first panel.

0016According to this invention there is also provided a garage door insulating kit. The kit includes at least eight sections of insulation material and at least sixteen clips.

0017According to yet another aspect of this invention, there is provided a connector. The connector includes a head. Two diametrically-opposed resilient latching elements project from that head. In addition, a first locking shoulder extends at least partially between the latching elements. Further, at least one latching element of the two diametrically-opposed latching elements includes a latching shoulder adjacent a distal end opposite the head.

0018Additional objects, features and advantages of the present invention will become more readily apparent from the following detailed description of preferred embodiments when taken in conjunction with the drawings wherein like reference numerals refer to corresponding parts in the several views.

BRIEF DESCRIPTION OF THE DRAWINGS

0019The accompanying drawings incorporated herein and forming a part of the specification, illustrate several aspects of the present invention and together with the description serve to explain certain principles of the invention. In the drawings:

0020<figref idref="DRAWINGS">FIG. 1</figref> is a cross-sectional view of a garage door including the insulation system of the present invention.

0021<figref idref="DRAWINGS">FIG. 2</figref> is rear (a.k.a interior) view of a garage door including the insulation system of the present invention.

0022<figref idref="DRAWINGS">FIG. 2A</figref> is a detailed view of one possible embodiment of the garage door panel incorporating a raised contour in the doorway.

0023<figref idref="DRAWINGS">FIG. 3</figref> is a side elevational view of a securing clip of the present invention.

0024<figref idref="DRAWINGS">FIG. 4</figref> is a side elevational view showing two cooperating clips used to secure a blanket of insulation material to a panel of a garage door.

0025<figref idref="DRAWINGS">FIG. 5</figref> is a cross section of the clip with the two connectors fully seated, taken along line <b>5</b>-<b>5</b> of <figref idref="DRAWINGS">FIG. 4</figref>.

0026<figref idref="DRAWINGS">FIG. 6</figref> is a top plan view of an installation kit of the present invention.

DETAILED DESCRIPTION

0027Reference is now made to <figref idref="DRAWINGS">FIG. 1</figref> generally illustrating the insulation system <b>10</b> of the present invention. The insulation system comprises a layer of insulation material <b>12</b> that is affixed to a major surface <b>14</b> of a panel <b>16</b> by at least one securing clip <b>18</b>. Four securing clips <b>18</b> are illustrated in <figref idref="DRAWINGS">FIG. 1</figref>. It should be appreciated, however, that substantially any number of securing clips <b>18</b> may be utilized as suited for any particular application.

0028As illustrated in <figref idref="DRAWINGS">FIG. 1</figref>, the insulation material <b>12</b> includes a first side <b>20</b> and a second side <b>22</b>. The first side <b>20</b> of the insulation material <b>12</b> is provided adjacent to the major surface <b>14</b> of the panel <b>16</b>. An optional facing <b>24</b> may be provided on the second side <b>22</b> of the insulation material <b>12</b>. When properly mounted, each securing clip extends through the insulation material <b>12</b> and the optional facing <b>24</b>, if it is present. The facing <b>24</b> may be made from any suitable facing material including, but not limited to, polymers, such as vinyl, nylon or polyester, polymer films, paper, foil, cloth, woven or non-woven fabric or combinations thereof.

0029The insulation material <b>12</b> may be any insulation material known, including but not limited to, fiberglass insulation batting, mineral wool, polymer fibers, foams, blown-in foams, flexible foams, natural fibers and combinations thereof. In one embodiment, the insulation material <b>12</b> may have an R-value of between about 2 to about 100, or about 2 to about 50, or about 2 to about 40, or about 2 to about 30, or about 2 to about 20, or about 2 to about 10. The panel <b>16</b> may be any panel including, but not limited to, walls, doors and garage doors. The insulation system may also be used on industrial doors, delivery trucks, trailers, sheds, pet enclosures, metal buildings, ice shanties, hunting blinds, campers, boats or any other structure having panels where insulation may be necessary. Such panels <b>16</b> may be constructed from substantially any appropriate material including, but not limited to, polymer materials, wood, metal, steel, fiberglass composite materials and the like.

0030As illustrated in <figref idref="DRAWINGS">FIG. 2</figref>, the insulation system <b>10</b> of the present invention is particularly useful on a garage door <b>26</b>. The illustrated garage door <b>26</b> includes two rows of panels <b>16</b>. Four panels <b>16</b> are provided in each row. The height of the garage door <b>26</b> is determined by the number of panels <b>16</b> used and is equivalent to the height of the garage entry opening. The width of the two rows of panels <b>16</b> is equivalent to the width of the garage entry opening so that the height and width of the garage door is equivalent to the height and width of the garage entry opening. A frame member <b>30</b> is provided at the top of each panel <b>16</b>. Similarly, a frame member <b>32</b> is provided at the bottom of each panel <b>16</b>. The two rows of panels <b>16</b> are joined together at the mid section by the frame members <b>34</b>. Similar frame members <b>36</b> are provided at the ends of the panel rows and define the left and right margins of the garage door <b>26</b>. A series of hinges <b>38</b> connect the adjacent frame members <b>34</b>, <b>36</b>. These hinges <b>38</b> allow the garage door <b>26</b> to fold during opening and closing. Typically a sealing member <b>40</b> is provided at the bottom of the garage door <b>26</b> to seal between the door and an underlying concrete pad.

0031As illustrated in <figref idref="DRAWINGS">FIG. 2A</figref> one or more of the panels <b>16</b> may have a major surface <b>14</b> that is contoured. Thus, the panel <b>16</b> carries a top frame member <b>30</b> and a bottom frame member <b>32</b>. The major face <b>14</b> includes a door tray <b>28</b> comprising a raised contour. Typically the layer of insulation material <b>12</b> is sufficiently resilient and compressible to accommodate the raised contour of the door tray <b>28</b>. However, it should be appreciated that the layer of insulation material <b>12</b> may alternatively, be manufactured to include a cavity to accommodate the door tray <b>28</b> if desired.

0032As best illustrated in <figref idref="DRAWINGS">FIGS. 2 and 4</figref>, at least one clip, generally designated by reference numeral <b>18</b> is utilized to secure the layer of insulation material <b>12</b> to the major surface <b>14</b> of each panel <b>16</b>. In the illustrated embodiment, each clip <b>18</b> is affixed to the panel <b>16</b> with an adhesive such as a pressure sensitive adhesive as manufactured by MACtac of Stow, Ohio. In the embodiment illustrated in <figref idref="DRAWINGS">FIG. 2</figref>, two clips <b>18</b> are provided to secure each layer of insulation <b>12</b> to each panel <b>16</b>.

0033As best illustrated in <figref idref="DRAWINGS">FIGS. 3-5</figref>, each clip <b>18</b> comprises first and second connectors <b>44</b>, <b>44</b>′. In the illustrated embodiment the first and second connectors <b>44</b>, <b>44</b>′ are identical. As best illustrated in <figref idref="DRAWINGS">FIG. 3</figref>, each connector <b>44</b> includes a head <b>46</b>. In the illustrated embodiment the head <b>46</b> is enlarged and disc shaped. Two diametrically-opposed resilient latching elements <b>48</b> project from the head <b>46</b>. A first locking shoulder <b>50</b> extends at least partially between the latching elements <b>48</b>. A second locking shoulder, not illustrated in <figref idref="DRAWINGS">FIG. 3</figref> but shown in <figref idref="DRAWINGS">FIG. 5</figref> at <b>51</b>′, is provided opposite the first locking shoulder <b>50</b>′. At least one latching element <b>48</b> of the two diametrically-opposed resilient latching elements <b>48</b> includes a latching shoulder <b>52</b> adjacent a distal end opposite the head <b>46</b> (two latching shoulders <b>52</b> are illustrated in <figref idref="DRAWINGS">FIG. 3</figref>).

0034As further illustrated in <figref idref="DRAWINGS">FIG. 3</figref>, at least one latching element <b>48</b> includes beveled side walls <b>56</b> and a pair of opposed, projecting detents <b>54</b> adjacent the distal end. In addition a series of aligned notches <b>58</b> are provided in the beveled side walls <b>56</b>. The last of the notches <b>58</b> is elongated to allow for full seating of the connectors <b>44</b>. Further, a first cam surface <b>60</b> is provided adjacent the latching shoulder <b>52</b> and the distal end of the connector <b>44</b> and a second cam surface <b>62</b> is provided adjacent the locking shoulder <b>50</b>. Another second cam surface is provided on the opposite side of the connector <b>44</b> but it is not visible in <figref idref="DRAWINGS">FIG. 3</figref>.

0035First and second connectors <b>44</b> and <b>44</b>′ are interconnected as illustrated in <figref idref="DRAWINGS">FIGS. 4 and 5</figref> by rotating one of the connectors <b>44</b> through 90° so that the latching elements <b>48</b>, <b>48</b>′ of the two connectors are 90° out of phase. The two connectors <b>44</b>, <b>44</b>′ are then pushed together (note action arrows A in <figref idref="DRAWINGS">FIG. 4</figref>). When fully seated, the first and second latching shoulders <b>52</b> of the first connector <b>44</b> engage the opposed locking shoulders <b>50</b>′, <b>51</b>′ of the second connector <b>44</b>′. The cooperating first and second cam surfaces <b>60</b>, <b>62</b>′ allow for smooth interconnection. As the connectors <b>44</b>, <b>44</b>′ are pushed together, the projecting detents <b>54</b> of the first connector <b>44</b> engage in the notches <b>58</b>′ of the second connector <b>44</b>′ to provide a sensory signal to the user that the connectors <b>44</b>, <b>44</b>′ are properly aligned and moving toward complete connection. The final click that signals full seating occurs when the latching shoulders <b>52</b> snap into the cavities <b>66</b>′ of the second connector <b>44</b>′ and engage with the cooperating locking shoulders <b>50</b>′, <b>51</b>′. It should be appreciated that the detents (not shown) of the connector <b>44</b>′ engage in the notches (not shown) of the connector <b>44</b> and the latching shoulders (not shown) of the connector <b>44</b>′ engage the locking shoulders (not shown) of the connector <b>44</b> at the opposite end of the clip <b>18</b> when the connectors <b>44</b>, <b>44</b>′ are fully seated. The resilient nature of the latching elements <b>48</b>, <b>48</b>′ ensures the positive connection. The enlarged head <b>46</b>′ engages a significant surface area of the insulation material <b>12</b> or optional facing <b>24</b> so as to prevent the insulation material from pulling off the connector <b>18</b> under the pull of gravity and during operation of the garage door <b>26</b>.

0036The method of installing a layer of insulation material <b>12</b> on a panel <b>16</b> will now be described in detail with reference to <figref idref="DRAWINGS">FIG. 4</figref>. The method includes affixing at least one clip <b>18</b> to a major surface <b>14</b> of a panel <b>16</b>. More specifically, the first connector <b>44</b> of the clip <b>18</b> may be affixed to the major surface <b>14</b> by means of an adhesive such as a pressure sensitive adhesive. This is followed by the positioning of a portion or section of insulation material <b>12</b> over the first connector <b>44</b> so that the first connector extends through the insulation material. It should be noted that the insulation material <b>12</b> may be cut or slit at the point of insertion so as to more easily permit the connector <b>44</b> to extend through the layer <b>12</b>. When the layer of insulation material <b>12</b> is properly seated on the connector <b>44</b>, the first side <b>20</b> of the insulation material abuts the major surface <b>14</b> of the panel <b>16</b>. Further, the distal end of the connector <b>44</b> extends through the optional facing <b>24</b> on the second side <b>22</b> if that facing is present.

0037As shown in <figref idref="DRAWINGS">FIG. 2</figref>, two clips <b>18</b> may be installed to secure each insulation layer <b>12</b> to each panel <b>16</b> of a garage door <b>26</b>. Of course, it should be noted that fewer or more clips may be used depending on the size of the panel <b>16</b> and the size and/or weight of the insulation layer <b>12</b>. Further, depending on the application, the insulation layer <b>12</b> may be one large piece or several smaller pieces. As illustrated in <figref idref="DRAWINGS">FIG. 2</figref>, a garage door <b>26</b> includes eight panels <b>16</b> with each panel <b>16</b> being covered by a single layer and section of insulation material <b>12</b> and each layer of insulation material being held in place by two clips <b>18</b>. Of course, it should also be appreciated that more than one layer of insulation may be attached to the panels <b>16</b> if desired.

0038Reference is now made to <figref idref="DRAWINGS">FIG. 6</figref> illustrating a garage door insulating kit <b>70</b> of the present invention. The kit <b>70</b> comprises at least eight sections of insulation material <b>12</b> and at least sixteen securing clips <b>18</b>. As further illustrated, the insulating kit <b>70</b> may also include a pair of vinyl gloves <b>72</b> and installation instructions <b>74</b>. In one possible embodiment the securing clips <b>18</b> have pre-applied adhesive <b>78</b> on at least one end. Further, it should be appreciated that the insulation material <b>12</b> may include the optional vinyl facing <b>24</b> and/or at least two pre-cut slits <b>76</b> through which the clips <b>18</b> are secured.

0039The foregoing description of the preferred embodiments of the present invention have been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings.

0040For example, while the first and second connectors <b>44</b>, <b>44</b>′ of the illustrated clip <b>18</b> are identical, it should be appreciated that the connectors are not required to be identical. For example, the first and second connectors <b>44</b>, <b>44</b>′ may comprise cooperating male and female components if desired. Further, the connectors <b>44</b>, <b>44</b>′ may be secured together by snap action, friction fit, cooperating threads or any other appropriate interconnecting structure. Thus, a clip, such as that taught in U.S. Pat. No. 5,176,465 may be used. Such a clip includes cooperating male and female connectors. When the male connector is fully seated in the female connector, holes in the two connectors are aligned. A locking means, such as a pin, tab, screw or nail is then inserted in these holes to secure the two connectors of the clip together. Further, another type of clip may be used, such as snap rivets manufactured by ITW Fastex (Des Plaines, Ill.).

0041In the illustrated embodiment, an adhesive is utilized to affix the clip <b>18</b> and, more specifically, the first connector <b>44</b>, to the major surface <b>14</b> of the panel <b>16</b>. It should be appreciated that alternative securing means may be used including, for example, magnets, wire, screws, VELCRO, hook and loop fasteners, tape, nails or combinations thereof. Further, while the insulation layer <b>12</b> is illustrated with only a single optional facing layer <b>24</b>, it should be appreciated that the insulation layer may be fully encapsulated with a facing on all sides or encapsulated on all sides except the side adjacent to the garage door <b>26</b>.

0042The embodiments were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled. The drawings and preferred embodiments do not and are not intended to limit the ordinary meaning of the claims in their fair and broad interpretation in any way.